High density polyurethane and polyisocyanurate construction boards and composite boards

Abstract

A covered roof includes a roof deck, an insulation board, and a coverboard. The insulation board includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, has a density that is less than 2.5 pounds per cubic foot, and has a first planar surface and a second planar surface, each having a facer positioned adjacent thereto. The coverboard includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, has a density greater than about 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, each having a facer positioned adjacent thereto.

What is claimed is: 
     
         1 . A covered roof comprising:
 a) a roof deck;   b) an insulation board including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said insulation board having a density that is less than 2.5 pounds per cubic foot, and said insulation board having a first planar surface and a second planar surface, said first planar surface and said second planar surface each having a facer positioned adjacent thereto;   c) a coverboard including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said coverboard having a density greater than 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, said first planar surface and said second planar surface each having a facer positioned adjacent thereto; and   d) a membrane covering.   
     
     
         2 . The roof of  claim 1 , where the facer of said coverboard is formed of materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof. 
     
     
         3 . The roof of any of the previous claims, where said insulation board is positioned above said roof deck, said coverboard is positioned above said insulation board, and said membrane is positioned above said coverboard. 
     
     
         4 . The roof of any of the previous claims, where the coverboard has a thickness that is greater than 0.5 inches. 
     
     
         5 . A high density construction board comprising:
 a cellular body having a first planar surface and a second planar surface, a first facer adjacent said first planar surface and a second facer adjacent said second planar surface, wherein said cellular body includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate and has a density greater than 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, and wherein said first facer and said second facer are formed from materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof.   
     
     
         6 . The construction board of  claim 5 , where the coverboard has a thickness that is greater than 0.5 inches. 
     
     
         7 . A method comprising:
 a) applying an insulation board above a roof deck, said insulation board including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said insulation board having a density that is less than 2.5 pounds per cubic foot; and   b) applying a coverboard over the insulation board, wherein the coverboard includes a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said coverboard having a density that is greater than 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, said first planar surface and said second planar surface having a facer positioned adjacent thereto.   
     
     
         8 . The method of  claim 7 , where the facer of said coverboard is formed of materials selected from the group consisting of coated glass fiber mats, uncoated glass fiber mats, chopped glass, and combinations thereof. 
     
     
         9 . The method of  claim 7 , where the coverboard has a thickness that is greater than 0.5 inches. 
     
     
         10 . A method of protecting an insulation board installed on a flat or low-sloped roof, where the insulation board has a density of greater than 1.5 pounds per cubic foot, as determined by ASTM C303, the method comprising the step of:
 a) providing a coverboard including a polyurethane, a polyisocyanurate, or a mix of polyurethane and polyisocyanurate cellular structure, said coverboard having a density greater than 2.5 pounds per cubic foot and less than 6 pounds per cubic foot, an iso index of at least 175, and a first planar surface and a second planar surface, said first planar surface and said second planar surface each having a facer positioned adjacent thereto; and   b) installing the coverboard over said insulation board.